An Automated Diagnosis Methodology for Manufacturing and Assembly Failures of Refrigerator Compressors on Production Line Using Vibration Data

Yıl 2023, Cilt: 4 Sayı: 1, 25 - 34, 24.07.2023

Ali Aykan Solmaz Alperen Acar

Öz

This paper presents, the design of a system that performs automated detection and diagnosis of several types of failure with time-frequency (Fast Fourier Transform) based analysis of vibration data taken from hermetic compressors used in home appliances. The objective of this paper is to investigate the vibration characteristic of noisy appliances and cooling faults. Experimental studies were conducted for finding the correlation between failures and vibration data. Vibration data of appliances for the various fault cases were collected and correlation was determined between the inputs and outputs with the help of regression analysis. The fault characteristic for the huge amount of time-frequency data was transferred into a central data lake on a cloud for fault classification. Thus characteristic algorithm was applied to automate the production process. As a result of the study, it has been revealed that the noise level of the compressors used in refrigerators with 74.41% reliability can be calculated through the vibration sensor.

Anahtar Kelimeler

Failure diagnosis, Compressor, Vibration, Noise Level

Kaynakça

• [1] Radermacher, R., & Kim, K., (1996). Domestic refrigerators: recent developments. International Journal of Refrigeration, 19(1), 61–69. [CrossRef]
• [2] Boyacı, S., Ekren, N., & Görgülü, S., (2019). Test system design for automatic fault detection of electromechanical components used in refrigerators. International Journal of Engineering Design, and Technology 1(2), 42–50.
• [3] Oldham, B. C. (1947). Evolution of machine and plant design. Proc. Institution of Refrigeration 43, 59–82.
• [4] ASHRAE. (2018). Refrigeration Handbook (SI Edition). American Society of Heating, Refrigerating and Air-Conditioning Engineers, Inc.
• [5] Tezcan, A. (2018). Modelling and optimization of double cycled condenser where is used on built in refrigerators [Master Thesis]. Trakya University, Institute of Science.
• [6] Guo, J., Luo, J., Guo, Y., Pan, X., Fang, X., & Wu, X. (2015). Noise test and control for household refrigerator compressor. IEEE International Conference on Information and Automation, August 8–10, 2015 Lijiang, China. [CrossRef]
• [7] Dianov, A. (2020). Estimation of the mechanical position of reciprocating compressor for silent stoppage. IEEE Open Journal of Power Electronics 2, 64–73. [CrossRef]
• [8] Steffenato, S., Marcer, M., & Ayllon, P. O. (1999). Correlation between refrigerator noise and compressor vibrations development of a new measurement method for compressor vibration. Sixth International Congress on Sound and Vibration July 5–8, 1999 Copenhagen, Denmark.
• [9] Bogdanovská, G., Molnár, V., & Fedorko, G. (2018). Failure analysis of condensing units for refrigerators with refrigerant R134a, R404A. International Journal of Refrigeration 100, 208–219. [CrossRef]
• [10] Park, S., Kim, W., & Kim, S. (2014). A numerical prediction model for vibration and noise of axial flux motors. IEEE Transactions on Industrial Electronics, 61(10), 5757–5762. [CrossRef]
• [11] Tsypkin, M. (2014). Vibration of induction motors operating with variable frequency drives - a practical experience. IEEE 28th Convention of Electrical and Electronics Engineers in Israel (IEEEI), December 3–5, 2014 Eilat, Israel. [CrossRef]
• [12] Mais, J. (2002). Spectrum analysis: The key features of analyzing spectra. Accessed on Jan 21, 2020. https://www.skf.com/binary/tcm:12-3997/CM5118%20EN%20Spectrum%20Analysis .pdf
• [13] Biernat, A., Jackiewicz, K., & Bienkowski, K. (2017). Vibration analysis of SRM designed for motoring and generating operation with spread spectrum current control. 19th European Conference on Power Electronics and Applications (EPE'17 ECCE Europe). September, 11–14, 2017 Warsaw, Poland. [CrossRef]
• [14] Jokic, S., Cincar, N., & Novakovic, B. (2018). The analysis of vibration measurement and current signature in motor drive faults detection. 17th International Symposium Infoteh-Jahorina (Infoteh). March 21–23, 2018 East Sarajevo, Bosnia-Herzegovina. [CrossRef]
• [15] Pindoriya, R.M., Mishra, A.K., Rajpurohit, B.S., & Kumar, R.V. (2018). An analysis of vibration and acoustic noise of BLDC motor drive. IEEE Power & Energy Society General Meeting (PESGM), 05-10 August 2018. [CrossRef]
• [16] Alekseev, V. V., Kalyakin, I. V., Konovalova, V. S., Konovalova, P. G., Perkova, & A. G., (2015). Diagnostic features identification algorithm according to vibration parameters of a compressor installation. XVIII International Conference on Soft Computing and Measurements (SCM’15), May, 19 – 21, 2015 St. Petersburg, Russia. [CrossRef]
• [17] Turgut, Y. (2013). Machine vision based automatic fault control system. [Master Thesis] Marmara University, Institute of Pure and Applied Sciences.
• [18] Behfar, A., Yuill, D., & Yu, Y., (2017). Automated fault detection and diagnosis methods for supermarket equipment (RP-1615). Science and Technology for the Built Environment, 23(8), 1253–1266. [CrossRef]
• [19] Zhao, J., Li, H., & Wang, S. (2013). Failure causes and countermeasures analysis for a large-scale reciprocating compressor vibration. International Conference on Quality, Reliability, Risk, Maintenance, and Safety Engineering (QR2MSE), July 15–18, 2013 Chengdu, China. [CrossRef]
• [20] Ozsipahi, M., Cadirci, S., Gunes, H., Sarioglu, K., & Kerpicci, H., (2014). A numerical study on the lubrication system for a hermetic reciprocating compressor used in household refrigerators. International Journal of Refrigeration 48, 210–220. [CrossRef]
• [21] Tang, M., Zou, M., Wang, M., & Tian, C. (2018). Fourier series analysis applied in linear compressorvibration analysis. IEEE International Conference on Mechatronics and Automation (ICMA’18), August 5–8, 2018 Changchun, China. [CrossRef]
• [22] BKSV. (2020). Product data. Accessed on Feb 15, 2020. https://www.bksv.com/media/doc/bp2464.pdf
• [23] Lally, J. (2020). Accelerometer selection consideration charge and integrated circuit piezoelectric. Accessed on Feb 10, 2020. https://www.pcb.com/contentstore/MktgContent/LinkedDocuments/Technotes/TN-17_VIB-0805.pdf
• [24] Brüel & Kjaer. (1982). Measuring vibration, Accessed on Feb 29, 2020. https://www.bksv.com/media/doc/ br0094.pdf.
• [25] Shin, H. J., Choi, J. Y., Park, H., & Jang, S. M. (2012). Vibration analysis and measurements through prediction of electromagnetic vibration sources of permanent magnet synchronous motor based on analytical magnetic field calculations. IEEE Transactions on Magnetics 48(11), 4216–4219. [CrossRef]
• [26] Chang, R.F., Lu, C.N., & Hsiao, T.Y. (2005). Prediction of frequency response after generator outage using regression tree. IEEE Transactions on Power Systems, 20(4), 2146–2147. [CrossRef]
• [27] Pereira, M. T., Inês Bento, M., Ferreira, L. P., Sá, J.C., & Silva, F. J. G. (2019). Using six sigma to analyse customer satisfaction at the product design and development stage. Procedia Manufacturing, 38, 1608– 1614. [CrossRef]
• [28] Costa, J. P., Lopes, I. S., & Brito, J. P. (2019). Six Sigma application for quality improvement of the pin insertion process. Procedia Manufacturing, 38, 1592–1599. [CrossRef]